U.S. patent application number 15/393416 was filed with the patent office on 2017-04-20 for method of manufacturing electrical storage device and method of manufacturing electrode.
The applicant listed for this patent is Murata Manufacturing Co., Ltd.. Invention is credited to Masahiro Otsuka.
Application Number | 20170110713 15/393416 |
Document ID | / |
Family ID | 55064059 |
Filed Date | 2017-04-20 |
United States Patent
Application |
20170110713 |
Kind Code |
A1 |
Otsuka; Masahiro |
April 20, 2017 |
METHOD OF MANUFACTURING ELECTRICAL STORAGE DEVICE AND METHOD OF
MANUFACTURING ELECTRODE
Abstract
A method of manufacturing an electrical storage device that
includes an electrode including a cutout part in which a terminal
unit including no active material layer is provided. The electrical
storage device is manufactured by forming an active material layer
having a partially cut-out rectangular shape on a surface of a
collector base material to form an electrode base material. The
electrode base material is cut to form an electrode that includes a
terminal unit formed from part of the electrode base material in
which the active material layer is not provided.
Inventors: |
Otsuka; Masahiro;
(Nagaokakyo-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Murata Manufacturing Co., Ltd. |
Nagaokakyo-shi |
|
JP |
|
|
Family ID: |
55064059 |
Appl. No.: |
15/393416 |
Filed: |
December 29, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP2015/067780 |
Jun 19, 2015 |
|
|
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15393416 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01G 11/52 20130101;
H01M 2002/0205 20130101; H01M 4/04 20130101; H01M 4/13 20130101;
H01M 4/043 20130101; H01M 10/052 20130101; H01M 4/70 20130101; Y02E
60/10 20130101; H01G 11/26 20130101; H01G 11/28 20130101; H01G
11/70 20130101; H01G 11/86 20130101; H01M 4/139 20130101; H01M 2/26
20130101; H01M 10/0585 20130101; Y02E 60/13 20130101; H01G 11/74
20130101; H01M 2/021 20130101; H01M 10/0463 20130101 |
International
Class: |
H01M 4/04 20060101
H01M004/04; H01G 11/28 20060101 H01G011/28; H01G 11/86 20060101
H01G011/86; H01M 2/26 20060101 H01M002/26; H01G 11/70 20060101
H01G011/70; H01M 4/139 20060101 H01M004/139; H01M 4/70 20060101
H01M004/70; H01G 11/52 20060101 H01G011/52; H01G 11/74 20060101
H01G011/74 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 10, 2014 |
JP |
2014-141855 |
Claims
1. A method of manufacturing an electrical storage device, the
method comprising: forming a first active material layer having a
partially cut-out rectangular shape on a first surface of a
collector base material to form an electrode base material; cutting
the electrode base material to form a first electrode that includes
a terminal unit formed from part of the electrode base material in
which the active material layer is not provided; and interposing a
separator between the first electrode and a second electrode to
form the electrical storage device.
2. The method of manufacturing an electrical storage device
according to claim 1, further comprising forming a second active
material layer on a second surface of the collector base material
opposite the first surface.
3. The method of manufacturing an electrical storage device
according to claim 2, wherein the second active material layer
includes a second cutout part, and the second active material layer
is formed such that the cutout part of the first active material
layer matches the second cutout part of the second active material
layer.
4. The method of manufacturing an electrical storage device
according to claim 2, wherein the second active material layer is
shaped so as to cover the cutout part of the first active material
layer.
5. The method of manufacturing an electrical storage device
according to claim 1, wherein a plurality of the first active
material layers are formed on the first surface of the collector
base material, and the plurality of the first active material
layers are formed such that the respective cutout parts of adjacent
active material layers partially overlap with each other.
6. The method of manufacturing an electrical storage device
according to claim 5, further comprising forming a plurality of
second active material layers on a second surface of the collector
base material opposite the first surface.
7. The method of manufacturing an electrical storage device
according to claim 6, wherein the plurality of second active
material layers each includes a second cutout part, and the
plurality of second active material layers are formed such that
respective cutout parts of the first active material layers match
respective second cutout parts of the plurality of second active
material layers.
8. The method of manufacturing an electrical storage device
according to claim 6, wherein the plurality of second active
material layers are shaped so as to cover the cutout parts of the
plurality of first active material layers.
9. The method of manufacturing an electrical storage device
according to claim 1, wherein a plurality of the first active
material layers are formed on the first surface of the collector
base material, and the plurality of the first active material
layers are formed such that the respective cutout parts of four
adjacent active material layers are continuous with each other.
10. The method of manufacturing an electrical storage device
according to claim 9, further comprising forming a plurality of
second active material layers on a second surface of the collector
base material opposite the first surface.
11. The method of manufacturing an electrical storage device
according to claim 10, wherein the plurality of second active
material layers each includes a second cutout part, and the
plurality of second active material layers are formed such that
respective cutout parts of the first active material layers match
respective second cutout parts of the plurality of second active
material layers.
12. The method of manufacturing an electrical storage device
according to claim 10, wherein the plurality of second active
material layers are shaped so as to cover the cutout parts of the
plurality of first active material layers.
13. The method of manufacturing an electrical storage device
according to claim 1, further comprising pressing the electrode
base material after the formation of the first active material
layer.
14. A method of manufacturing an electrode, the method comprising:
forming a first active material layer having a partially cut-out
rectangular shape on a first surface of a collector base material
to form an electrode base material; and cutting the electrode base
material to form a first electrode that includes a terminal unit
formed from part of the electrode base material in which the active
material layer is not provided.
15. The method of manufacturing an electrode according to claim 14,
further comprising forming a second active material layer on a
second surface of the collector base material opposite the first
surface.
16. The method of manufacturing an electrical storage device
according to claim 15, wherein the second active material layer
includes a second cutout part, and the second active material layer
is formed such that the cutout part of the first active material
layer matches the second cutout part of the second active material
layer.
17. The method of manufacturing an electrical storage device
according to claim 15, wherein the second active material layer is
shaped so as to cover the cutout part of the first active material
layer.
18. The method of manufacturing an electrical storage device
according to claim 14, wherein a plurality of the first active
material layers are formed on the first surface of the collector
base material, and the plurality of the first active material
layers are formed such that the respective cutout parts of adjacent
active material layers partially overlap with each other.
19. The method of manufacturing an electrical storage device
according to claim 14, wherein a plurality of the first active
material layers are formed on the first surface of the collector
base material, and the plurality of the first active material
layers are formed such that the respective cutout parts of four
adjacent active material layers are continuous with each other.
20. The method of manufacturing an electrical storage device
according to claim 14, further comprising pressing the electrode
base material after the formation of the first active material
layer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of International
application No. PCT/JP2015/067780, filed Jun. 19, 2015, which
claims priority to Japanese Patent Application No. 2014-141855,
filed Jul. 10, 2014, the entire contents of each of which are
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of manufacturing
an electrical storage device and a method of manufacturing an
electrode.
BACKGROUND OF THE INVENTION
[0003] Conventionally, an electrical storage device such as a
secondary battery has been used for various kinds of instruments
such as a mobile device and the like. The secondary battery
includes, for example, a positive electrode, a negative electrode,
a separator that separates the positive electrode and the negative
electrode from each other, and an electrolyte. The positive
electrode and the negative electrode each include a collector and
an active material layer provided on the collector.
[0004] Patent Document 1 discloses an exemplary method of
manufacturing an electrode such as a positive electrode or a
negative electrode. In the method disclosed in Patent Document 1,
an active material layer is formed on an elongated collector in a
striped shape extending in the longitudinal direction of the
collector. Then, the collector on which the active material layer
is formed is cut at a predetermined interval in the width direction
thereof. In this manner, an electrode is manufactured.
[0005] Patent Document 1: Japanese Patent Application Laid-open No.
2001-327906
SUMMARY OF THE INVENTION
[0006] Recently, downsizing of an instrument on which an electrical
storage device is mounted has been increasingly requested. To
achieve the downsizing, an electrode is required to include a
cutout part in which a terminal is provided. A typical electrical
storage device includes a plurality of positive electrodes and
negative electrodes laminated with a separator interposed
therebetween, and a collector of each positive electrode needs to
be provided with a connection terminal unit for connection of the
plurality of positive electrodes with each other in parallel.
Similarly, a collector of each negative electrode needs to be
provided with a connection terminal unit. The connection terminal
units of the plurality of positive electrodes are adhered to a
positive electrode lead terminal by, for example, welding, and
externally extended. Similarly, the connection terminal units of
the plurality of negative electrodes are adhered to a negative
electrode lead terminal by, for example, welding, and externally
extended. Thus, when an electrode including a terminal unit in a
collector is formed by the method disclosed in Patent Document 1,
an active material layer provided on the terminal unit needs to be
removed after the electrode is manufactured. This leads to a need
for a method capable of excellently manufacturing an electrical
storage device that includes an electrode provided with a cutout
part in which a terminal unit including no active material layer is
provided.
[0007] The present invention is mainly intended to provide a method
capable of excellently manufacturing an electrical storage device
that includes an electrode provided with a cutout part in which a
terminal unit including no active material layer is provided.
[0008] In a method of manufacturing an electrical storage device
according to the present invention, the electrical storage device
includes an electrode. The electrode includes a rectangular
collector, a terminal unit, and an active material layer. The
collector is provided with a cutout part. The terminal unit is
provided continuously from the collector to protrude into the
cutout part. The active material layer is provided on the
collector. In the method of manufacturing an electrical storage
device according to the present invention, an electrode base
material is manufactured by forming a first active material layer
having a partially cut-out rectangular shape on a collector base
material. The electrode base material is then cut so as to form an
electrode that includes the terminal unit formed from part of the
electrode base material in which the first active material layer is
not provided.
[0009] In the method of manufacturing an electrical storage device
according to the present invention, a second active material layer
is preferably provided so as to overlap the cutout part of the
first active material layer.
[0010] In the method of manufacturing an electrical storage device
according to the present invention, a plurality of the active
material layers may be formed on the collector base material. In
this case, each of the active material layers is preferably
provided in the cutout part of adjacent one of the active material
layers on the collector base material.
[0011] Alternatively, the plurality of the active material layers
are preferably formed such that the cutout parts of the active
material layers adjacent to each other partially overlap with each
other.
[0012] Still further, the plurality of the active material layers
may be formed such that the cutout part of each of the active
material layers is positioned inside the plurality of the
continuously formed active material layers.
[0013] In the method of manufacturing an electrical storage device
according to the present invention, the electrode base material may
be pressed after the formation of the active material layer.
[0014] In a method of manufacturing an electrode according to the
present invention, an electrode base material is manufactured by
forming an active material layer having a partially cut-out
rectangular shape on a collector base material. The electrode base
material is then cut so as to form an electrode that includes the
terminal unit formed from part of the electrode base material in
which the active material layer is not provided.
[0015] The present invention can provide a method capable of
excellently manufacturing an electrical storage device that
includes an electrode provided with a cutout part in which a
terminal unit including no active material layer is provided.
BRIEF EXPLANATION OF THE DRAWINGS
[0016] FIG. 1 is a schematic plan view of an electrical storage
device according to a first embodiment.
[0017] FIG. 2 is a schematic side view of the electrical storage
device according to the first embodiment.
[0018] FIG. 3 is a schematic cross-sectional view of part of the
electrical storage device according to the first embodiment.
[0019] FIG. 4 is a schematic plan view of a first electrode in the
first embodiment.
[0020] FIG. 5 is a schematic plan view of a second electrode in the
first embodiment.
[0021] FIG. 6 is a schematic plan view of an electrode base
material in the first embodiment.
[0022] FIG. 7 is a schematic plan view of the electrode base
material in a second embodiment.
[0023] FIG. 8 is a schematic plan view of the electrode base
material in a third embodiment.
[0024] FIG. 9 is a schematic plan view of the electrode base
material in a fourth embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0025] Preferable embodiments of the present invention will be
described below. The following embodiments are merely exemplary.
The present invention is not limited to the following
embodiments.
[0026] In the drawings referred to in an embodiment or the like,
any members having effectively identical functions are denoted by
an identical reference symbol. The drawings referred to in an
embodiment or the like are schematically illustrated. For example,
and unless noted otherwise, a dimensional ratio of objects
illustrated in the drawings are not to scale and vary between
drawings.
First Embodiment
[0027] FIG. 1 is a schematic plan view of an electrical storage
device according to a first embodiment. FIG. 2 is a schematic side
view of the electrical storage device according to the first
embodiment. FIG. 3 is a schematic cross-sectional view of part of
the electrical storage device according to the first
embodiment.
[0028] The present embodiment is directed to a method of
manufacturing the electrical storage device 1 illustrated in FIGS.
1 to 3. First, the configuration of the electrical storage device 1
manufactured in the present embodiment will be described with
reference to FIGS. 1 to 3.
[0029] The electrical storage device 1 may be, for example, a
secondary battery or a capacitor. As illustrated in FIGS. 1 and 2,
the electrical storage device 1 is shaped in a rectangle, part of
which is cut out in a plane view. The shape of the electrical
storage device 1 is substantially an L shape in the plane view.
[0030] The electrical storage device 1 includes a housing 10. The
housing 10 is shaped in a rectangle provided with a cutout part
10a. The cutout part 10a of the housing 10 includes a first
terminal electrode 11 and a second terminal electrode 12.
[0031] The housing 10 includes a first electrode 21, a second
electrode 22, and a separator 23 (refer to FIG. 3). The first
electrode 21 includes a first collector 21a and first active
material layers 21b and 21c. The first active material layer 21b is
provided on one surface of the first collector 21a, and the second
active material layer 21c is provided on the other surface. The
second electrode 22 includes a second collector 22a and second
active material layers 22b and 22c. The second active material
layer 22b is provided on one surface of the second collector 22a,
and the second active material layer 22c is provided on the other
surface. In the electrical storage device 1, a plurality of the
first electrodes 21 and a plurality of the second electrodes 22 are
alternately laminated with the separator 23 interposed
therebetween.
[0032] One of the first and second electrodes 21 and 22 serves as a
positive electrode, and the other serves as negative electrode. The
collector of the electrode serving as the positive electrode may be
made of, for example, aluminum or aluminum alloy. The collector of
the electrode serving as the negative electrode may be made of, for
example, copper or copper alloy. The active material of the
positive electrode may be, for example, LiCoO.sub.2,
LiMn.sub.2O.sub.4, LiNi.sub.1/3Mn.sub.1/3Co.sub.1/3O.sub.2,
LiFePO.sub.4, or activated carbon. The active material of the
negative electrode may be, for example, graphite, hard carbon, soft
carbon, Li.sub.4Ti.sub.5O.sub.12, Si, Si oxide, Sn, or Sn
oxide.
[0033] FIG. 4 is a schematic plan view of the first electrode 21 in
the first embodiment. FIG. 5 is a schematic plan view of the second
electrode 22 in the first embodiment. In FIGS. 4 and 5 and FIGS. 6
to FIG. 9 to be described later, a hatched part indicates a part in
which an active material layer is formed.
[0034] As illustrated in FIG. 4, the first collector 21a is shaped
along the housing 10. The first collector 21a is shaped in a
rectangle provided with a rectangular cutout part 21a1. The first
collector 21a is connected with a terminal unit 21d. The terminal
unit 21d protrudes from the cutout part 21a1. The first active
material layers 21b and 21c are not provided on the terminal unit
21d.
[0035] As illustrated in FIG. 5, the second collector 22a is shaped
along the housing 10. The second collector 22a is shaped in a
rectangle provided with a rectangular cutout part 22a1. The second
collector 22a is connected with a terminal unit 22d. The terminal
unit 22d protrudes from the cutout part 22a1. The second active
material layers 22b and 22c are not provided on the terminal unit
22d.
[0036] The following describes a method of manufacturing the
electrical storage device 1.
[0037] As an outline, the first and second electrodes 21 and 22 and
the separator 23 are prepared. The first and second electrodes 21
and 22 are laminated on top of each other with the separator 23
interposed therebetween so as to obtain a laminated body. This
laminated body is housed in the housing 10 together with an
electrolyte. Thereafter, the terminal electrodes 11 and 12 are
formed to complete manufacturing of the electrical storage device
1.
[0038] The following describes a method of manufacturing the
electrodes 21 and 22 mainly with reference to FIG. 6. The
description is made on, as an example, a method of manufacturing
the first electrode 21. The second electrode 22 can be manufactured
by a method effectively same as the method of manufacturing the
first electrode 21.
[0039] First, a collector base material 31 (refer to FIG. 6) to be
formed as the collector 21a is prepared. An active material layer
32 having a partially cut-out rectangular shape is formed on both
surfaces of the collector base material 31. In this manner, an
electrode base material 30 including the collector base material 31
and the active material layer 32 is manufactured. In the present
embodiment, a plurality of the active material layers 32 are formed
in a matrix. The plurality of active material layers 32 are each
formed continuously relative to any adjacent active material
layers.
[0040] The method of forming each active material layer 32 is not
particularly limited. The active material layer 32 may be formed by
various printing methods such as a screen printing method and a
gravure printing method.
[0041] Next, the electrode base material 30 as a laminated body of
the active material layer 32 and the collector base material 31 is
pressed in the thickness direction thereof. In this manner, the
strength of adhesion between the active material layer 32 and the
collector base material 31 can be improved.
[0042] Next, the electrode base material 30 is cut along a cut line
L. Accordingly, the first electrode 21 including the terminal unit
21d formed as part of the electrode base material 30, in which the
active material layer 32 is not provided can be manufactured.
[0043] The collector base material 31 may have, for example, an
elongated shape. In this case, the electrodes 21 and 22 may be
formed by a roll-to-roll method. The collector base material 31 may
be shaped in a sheet.
[0044] As described above, in the present embodiment, the active
material layer 32 having a partially cut-out shape is formed.
Accordingly, the terminal unit 21d can be formed from part of the
electrode base material 30, in which the active material layer 32
is not provided. Unlike a case with an electrode base material on
which, for example, an active material layer having a striped shape
is provided, the active material layer otherwise provided on the
terminal unit does not need to be removed. Thus, the electrodes 21
and 22 can be easily manufactured.
[0045] In the process of pressing the electrode base material 30,
the collector base material 31 made of a ductile metal is
stretched. In the present embodiment, the active material layer 32
having a partially cut-out shape is formed. Thus, parts of the
active material layer 32 have widths different from each other. At
the pressing, lower pressure is applied to a wider part of the
active material layer 32, and higher pressure is applied to a
narrower part of the active material layer 32. As a result, the
collector base material 31 is likely to be stretched unevenly. For
this reason, it is preferable to provide the plurality of active
material layers 32 continuously from each other. In addition, the
plurality of active material layers 32 are preferably formed such
that a cutout part 32a of each active material layer 32 is
positioned inside the continuously provided active material layers
32.
[0046] The following describes other preferable embodiments of the
present invention. In the description below, any component having a
function effectively identical to that in the first embodiment is
denoted by an identical reference symbol, and description thereof
will be omitted.
Second Embodiment
[0047] FIG. 7 is a schematic plan view of the electrode base
material in a second embodiment.
[0048] As illustrated in FIG. 7, in the second embodiment, another
active material layer 33 is provided in the cutout part 32a of each
active material layer 32 on the collector base material 31. With
this configuration, the uneven pressure applied to the collector
base material 31 can be reduced. Accordingly, the uneven stretch of
the collector base material 31 caused in the process of pressing
the electrode base material 30 can be further reduced.
[0049] In the present embodiment, the active material layers 32 and
33 are provided continuously from each other. With this
configuration, the active material layers 32 and 33 are provided on
the entire collector base material 31 except for a part to be
formed as the terminal unit 21d of the collector base material 31
and a peripheral part thereof.
Third and Fourth Embodiments
[0050] FIG. 8 is a schematic plan view of the electrode base
material in a third embodiment. FIG. 9 is a schematic plan view of
the electrode base material in a fourth embodiment.
[0051] The first embodiment describes the example in which the
plurality of active material layers 32 are formed in a matrix,
facing in an identical direction. However, the present invention is
not limited thereto.
[0052] For example, as illustrated in FIG. 8, the plurality of
active material layers 32 may be formed such that the cutout parts
32a of four adjacent active material layers 32 are continuous with
each other.
[0053] For example, as illustrated in FIG. 9, the plurality of
active material layers 32 may be formed such that the cutout parts
32a of two adjacent active material layers 32 partially overlap
with each other. This configuration leads to a reduced waste part
of the collector base material 31. Accordingly, the electrodes 21
and 22 can be manufactured at a reduced cost.
DESCRIPTION OF REFERENCE SYMBOLS
[0054] 1: electrical storage device
[0055] 10: housing
[0056] 10a, 21a1, 22a1, 32a: cutout part
[0057] 11: first terminal electrode
[0058] 12: second terminal electrode
[0059] 21: first electrode
[0060] 21a: first collector
[0061] 21b, 21c: first active material layer
[0062] 21d, 22d: terminal unit
[0063] 22: second electrode
[0064] 22a: second collector
[0065] 22b, 22c: second active material layer
[0066] 23: separator
[0067] 30: electrode base material
[0068] 31: collector base material
* * * * *